Caldera Fulton

The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev. 3/5/13

Fulton Steam Horizontal Boiler

FB-S Series

100-800 Hp Installation, Operation and Maintenance Manual

The Fulton Companies 972 Centerville Road Pulaski, NY 13142 Telephone: (315) 298-5121 Facsimile: (315) 298-6390 www.fulton.com

Serial # __________________________ Model # __________________________ Fulton Order # __________________________ Sold To __________________________ Job Name __________________________ Date __________________________


Table of Contents

Introduction

Section 1 – Safety Warnings &

Precautions

Section 2 – Description &

Introductions

1. General

2. Specifications & Dimensions

Section 3 – Installation

1. Locating the boiler

2. Boiler room ventilation

3. Flue & chimney requirements

4. Recommended Water Conditions

5. Water Supply

6. Glossary of Water Terms

7. Valves

8. Electrical requirements

9. Gas supply

10. Oil supply

11. Installation check points

12. Cleaning

13. Boil-out of new unit

Section 4 – Controls & Burner

1. Boiler control panel

2. Burner

Section 5 – Operation

1. Fitting the boiler

2. Starting the burner

3. Daily operating test

4. Blowdown procedure

5. To shutdown the burner

6. Evaporation test

7. Fault finding

Section 6 – Maintenance

1. General

2. Weekly

3. Six monthly

4. Annually

5. Fitting new gasket

Section 7 - Warranty


Introduction

This operating manual presents information that will help to properly operate and care for the equipment.

Study its contents carefully. The unit will provide good service and continued operation if proper operating

and maintenance instructions are followed. No attempt should be made to operate the unit until the

principles of operation and all of the components are thoroughly understood. Failure to follow all

applicable instructions and warnings may result in severe personal injury or death.

These instructions must not be considered as a complete code of practice, nor should they replace

existing codes or standards which may be applicable.

The requirements and instructions contained in this section generally relate to the Fulton model FBS.

When installing a packaged unit, this entire section should be read to ensure that the installation work is

carried out correctly.

Prior to shipment, the following tests are made to assure the customer the highest standards of

manufacturing.

a) Material inspections

b) Manufacturing process inspections

c) ASME welding inspection

d) ASME hydrostatic test inspection

e) Electrical components inspection

f) Operating test

g) Final engineering inspection

h) Crating inspection

Note

The installation of the boiler should be carried ou t by competent personnel in accordance with the

standards of the National Fire Protection Associati on. All state and jurisdictional codes beyond

the scope of the applicable ASME boiler and pressur e vessel codes, for its corresponding

classification, should be followed in all cases. Ju risdictional authorities must be consulted prior

to installation.


All units are crated for crane lift transport. Under no circumstances should weight be allowed to bear on

the jacket, control panel, or fan housing of the boiler.

The customer should examine the boiler for any damage, especially the refractories around the burner.

Rigging your boiler into position should be handled by a competent rigger experienced in handling heavy

equipment.

Rigging Point (each side) *Lifting eyes on top may be used also*

Gas Train

ASME Stamping

Burner

Control Panel

Stack Connection

Pressure Gauge

Pressure Controls

Steam Outlet

Sight Glass

Manway

Safety Valve Connection

Rigging Point (each side) *Lifting eyes on top may be used also*


Section 1


Section 1 – Safety Warnings & Precautions

The following WARNINGS, CAUTIONS and NOTES appear in various chapters of this manual.

They are repeated on these safety summary pages as an example and for emphasis.

• WARNINGS must be observed to prevent serious injury or death to personnel.

• CAUTIONS must be observed to prevent damage or destruction of equipment or loss of

operating effectiveness.

• NOTES must be observed for essential and effective operating procedures, conditions,

and as a statement to be highlighted.

WARNING

Do not operate, service or repair this equipment un less you fully understand all applicable

sections of this manual.

Prior to commencing any internal work on any contro l panel or electrical junction box, the

power must be disconnected.

Do not allow others to operate, service or repair t his equipment unless they fully

understand all application sections of this manual, and are qualified to operate/maintain

the equipment.

Gauge glass valves need to be fully open during boi ler operation to prevent boiler water

damage in case of gauge glass failure.

Never tamper with low water cutoff sensors or circu itry.

Boiler blowdown water must be cooled to <140 oF prior to discharge to a drain. Failure to

use an approved blow off vessel with adequate cooli ng could cause personnel/equipment

damage.

A warm boiler will have very hot metal exposed. Car e should be taken not to touch these

open across without protective clothing.


CAUTIONS

A temperature exceeding 100 o F in the boiler room may cause premature failure o f

electrical components on the boiler control panel.

The water chemistry in the boiler must be kept with in limits outlined in this manual. Failure

to do so will likely cause premature boiler pressur e vessel failure and poor steam quality.

Boiler feed water temperature must be 140 o F or greater to prevent corrosion fatigue

cracking at the feed water nozzle.

The bolts that connect the boiler shell to the rail s need to be loosened slightly before the

boiler is warmed up to allow thermal expansion of t he pressure vessel. Failure to do so

will create unwanted pressure vessel stress.

NOTES

After installation is complete and prior to operati on the pressure vessel should be cleaned

or boiled out per instructions included in this man ual.

The normal water level is approximately the center of the water gauge glass.

To ensure that your Fulton Steam Boiler is kept ope rating safely and efficiently, follow the

maintenance procedures set forth in this manual.

It is normal for the boiler safety relief valve to weep water if the boiler is operated above

90% of the valve setpoint (i.e. weep will occur for a 100 psig valve if boiler is >90 psig).

To ensure the continued safety and efficiency of th e boiler, the schedule of maintenance

outlined in this section should be adhered to.

The boiler blow off operation should be done a mini mum of once during the day when the

boiler is at 10 PSIG or less.

After a new Fulton Boiler has been in operation for several months, pieces of burned metal

will be found in the space at the bottom of the boi ler. These pieces of metal are the

remains of a light gauge metal form which was used during manufacture for forming the


boiler insulation. This is a normal condition and d oes not affect the efficiency or the life of

the boiler in any way.

All secondary low water trips, flame failure trips or high steam pressure trips will require,

by code, a manual reset at the boiler.


Section 2


Section 2 – Description & Introductions

1. General

a) Fulton model FB-S is a three-pass, water back and corrugated furnace design

steam boiler. In the first pass, the flame and high temperature flue gas flows from

the front to the back of the furnace. Through the second pass pipes, high

temperature flue gas flows from the combustion furnace to the front chamber. In

the third pass, the flue gas passes through the third pass pipes to the back of the

boiler and vents out. Corrugated furnace highly increases the heat exchange

area, heat transfer efficiency and reduces the possible damage to the boiler

durability cased by heat expansion and cold contraction.

b) Boiler is designed and manufactured to comply with ASME Code, with maximum

working pressure of 1.0MPa (150 PSI).

c) The fully packaged boiler has passed the strict test before it is delivered to the

customer. The equipment will give long life and excellent service on the job if

proper operating and maintenance instructions are followed.

d) FB-S boiler is a cylindrical vessel, with horizontal tubes passing through and

connected to the front and rear tube sheets. The vessel contains the water and

absorbs the energy generated from the flame. The front door and rear door

provide the seal to contain the hot combustion gasses. Baffles designed into the

doors serve to redirect the combustion gasses through the various firetube

passages. The flame originates in the furnace. As the combustion gasses travel

down the furnace and through the various firetube channels, heat from the flame

and combustion gasses is transferred to the water. Transferred energy develops

into the required steam or hot water.

e) The front door and rear door make it easy to clean the combustion chamber. The

pressure vessel can be inspected and repaired by the manhole on the top and

handholes on the side or bottom. The general information in this manual applies

directly to boilers in sizes ranging from 1 ton/hr through 6 ton/hr steam output

boiler for the following fuels: gas, No.2-6 Oil, No2 Oil and Gas.

f) The boiler is equipped with an automatic burner for fully modulating output.


2. Specifications and Dimensions

Specifications

Model FB -S 100 125 150 200 250 300 400 500 650 800

Nominal steam output

(lbs/h) (1) 3450 4312 5175 6900 8625 10350 13800 17250 22425 27600

Design pressure (psig) 15/150 15/150 15/150 15/150 15/150 15/150 15/150 15/150 15/150 15/150

Water Volume (gallons) 779 924 924 1294 1585 1849 3594 4650 4677 5265

Maximum fuel consumption (2)

Light Oil (gp/h) 29 36 43 58 73 88 117 146 189 234

Heavy Oil (gp/h) 27 34 41 54 68 82 108 136 177 216

Natural Gas (ft3/h) 4156 5196 6235 8313 10,392 12,470 16,626 20,784 27,019 33,252

Note:

(1) All steam output lbs/hr ratings from 0 psig at 212F.

(2) Fuel consumption based on light oil 1, 40,000 BTU/gal, natural gas 1000 BTU/ft3, heavy oil 160,000

BTU/gal.

Connection

Model FB -S 100 125 150 200 250 300 400 500 650 800

Main steam valve (150 psig)

Flange 2.5 3 3 4 4 4 6 6 6 8

Safety valve connections

(150 psig) (in) 2 1.5 (2) 1.5 (2) 2 (2) 2 (2) 2.5 (2) 2.5 (2) 4 4 (2) 4 (2)

Main steam valve (15 psig) (in) Consult Factory

Safety valve (15 psig) (in) Consult Factory

Feed Water inlet line (in) 1.0 1.25 1.25 1.25 1.25 1.5 1.5 2 2 2

Blowdown line (in) 1.5 (2) 1.5 (2) 1.5 (2) 1.5 (2) 1.5 (2) 1.5 (2) 1.5 (2) 2 (2) 2 (2) 2 (2)

Flue diameter (in) 14 16 16 18 20 20 22 22 26 26

Note: Specifications and dimensions are approximate. Fulton reserves the right to change specifications and

dimensions.


Section 3


Section 3 – Installation

General

Note

It is essential that the installing shall be undert aken only by suitably qualified and

experienced personnel. Installation should comply w ith appropriate local and state codes

and standards.

1. Locating the Boiler

a) The boiler should be closed in dry surroundings on a level base, making sure that

there is sufficient room around the boiler to enable the operator and/or the

maintenance engineer to gain access to all parts of the boiler. Check location for

ease of water supply and electrical connections.

b) Place the boiler on a non-combustible floor with clearances to unprotected

combustible materials, including plaster or combustible supports.

c) It is necessary to have enough clearance from the floor to the ceiling for

removing of the burner and have the following clearance from boiler for servicing:

36” Min

36” Min

36” Min Clearance

48” Min


2. Boiler Room Ventilation

a) It is most important to provide free access of air to the boiler. To burn fuel

properly, it requires one square inch opening of fresh air for every 3, 000 BTU

input of fuel.

b) Proper ventilation of the boiler room is essential for good combustion. Install two

make up air openings, one at a low level (24” or 610mm from floor) and one at a

higher level in the boiler room wall. This will provide a flow of air to exhaust the

hot air from the boiler room.

c) The following openings are recommended for each size boiler:

Recommended Minimum Makeup Air Openings

Model FB -S 100 125 150 200 250 300 400 500 650 800 900

Minimum area (in2) 1437 1797 2156 2875 3593 4312 5750 7187 9343 11,500

d) Be sure the total BHP= proper make up air opening size. For instance, if you

have three 300 BHP boilers, it is a total BHP of 900, and the 900 BHP make up

air size is recommended.

Note

These measurements are subject to state and local r egulations. The

installation of exhaust fans in a boiler room is no t recommended. An

exhaust fan can create down draft in the stack or r estrict the burner’s air

supply which will result in poor combustion. It is essential that only fresh

air be allowed to enter the combustion air system. Foreign substances,

such as combustible volatiles and lint, in the comb ustion system can

create hazardous conditions.

3. Flue and Chimney Requirements

a) The flue from the appliance and the joint between this flue and the chimney are

sealed to prevent leakage of combustion products.

b) The top of the flue or chimney shall be higher than any roof within a radius of 10

meters.

c) Checks are made to ensure that the chimney is suitable for burner and that the

proposed installation complies with the local authority and other regulations

covering such installations.


d) If more than one appliance is connected to a common flue or chimney the cross-

section of the chimney should be adequate for the total volume of combustion

products from the appliances.

e) The total horizontal run of the boiler flue should not exceed 25% of the total

vertical rise. There should be an angle more than 15 degrees for the horizontal

run reducing the resistance of the combustion products and avoid rusting by

accumulating condensation in the flue.

f) The installer should check the draft with a meter at 0 to 0.15” W.C pressure with

the burner off. If the pressure is too low, a balancing damper may be used close

to the flue outlet to regulating the pressure of the draft.

4. Recommended Water Conditions

a) Following are recommendations for feed water and boiler water. Contact your

local water treatment professional for testing and treatment recommendations. It

is very important that a strict water treatment program be followed.

b) It is critical that the boiler pH water chemistry follow the attached schedule

whenever water is in the boiler. Solids that enter in with the feed water will

concentrate in the boiler. A regular schedule of boiler blowdown must be

maintained to prevent high solid concentrations from corroding the vessel or

forming deposits

Carbon Steel Parameter Feedwater Horizontal Boiler/SteamPac Wa ter pH 7.5-9.5 8.5-10.5 Feedwater Temperature

140F* ---

Hardness as CaCO3

< 2ppm < 15 ppm

Chlorides --- --- Total Alkalinity --- < 500 ppm Total Dissolved Solids

--- < 3000 ppm

Suspended Solids

No visual turbidity** No visual turbidity**

Total Orga nic Carbon

No sheen No foam + No sheen No foam +

Iron Colorless liquid++ Colorless liquid++ Dissolved Oxygen

<1 ppm* ND

Visual Oil ND ND Conductivity (µµµµS/cm)

--- < 4477

NOTES:

*Feedwater temperatures below 200oF will require an oxygen scavenger

** Suspended solids: Take a water sample. After the sample sits for 10 minutes, no solids should be visible.


+ Total Organic Carbon: Take a water sample. Shake vigorously for 30 seconds. No sheen or foam should be visible.

++ Iron: Take a water sample. Hold the sample against a white background. The water should have no visible yellow, red or orange tinge.

ND: None Detected.

5. Water Supply

a) The quality of the water used in the boiler will affect the life of the elements and

pressure vessel and it is strongly recommended that a competent water

treatment company be consulted prior to the installation of the boiler. PV

damaged due to adverse water conditions will not be replaced under warranty.

b) Natural feedwater supplies contain solids and dissolved gases. These may

promote scale, foaming, corrosion, and/or poor steam quality. To prevent this,

feedwater must be studied individually and treated accordingly. The treatment

should provide quality feedwater to the boiler such that corrosion and deposition

in the boiler will be minimized. Thermal cycling, dissolved oxygen, high or low pH

can all be major causes of corrosion. Untreated hardness is the major cause of

scale deposits. Poor quality feedwater requires increased blowdown and

increased chemical treatment costs to prevent boiler corrosion and scaling.

c) One way to lower the amount of dissolved gases in the boiler feed water is to

preheat the feedwater. This option injects live steam into the feedwater to

increase the water temperature to 180 degrees F or higher which removes

oxygen and carbon dioxide from the water.

d) RO/DIWater: Reverse Osmosis / Deionized water is water that all dissolved

solids have been removed. Very high purity steam quality can be obtained with

RO/DI water. RO/DI water has no buffering capacity and a pH of <6.5. It is

corrosive to carbon steel, however, not to stainless steel. Therefore, anytime

RO/DI water is used in a carbon steel vessel, pH neutralization is required to

bring the pH up to the required level.

e) The Fulton Warranty does not cover damage or failure that can be attributed to

corrosion, scale or fouling.

6. Glossary of Water Supply Terms

a) Dissolved Oxygen : Oxygen that is dissolved in the feedwater will cause the

steel in the boiler and the feedwater system to be attacked by the water in a

manner described as “pitting”. The pits that are produced can vary from tiny

depressions to holes large enough to penetrate the boiler metal and are usually

covered with tubercles of iron oxide. Once pitting starts, it may be extremely

hard to arrest. Pitting can proceed at a surprisingly rapid rate and can occur not


only in the boiler proper, but also in pre-boiler equipment such as ecomomizers,

feedwater tanks, and feedwater lines.

b) Sodium Sulfite : Its purpose is to chemically remove the dissolved oxygen left in

the feedwater after the feedwater has been mechanically deareated. Sodium

Sulfite reacts chemically with dissolved oxygen, producing sodium sulfate. Since

it is desirable to remove dissolved oxygen from the feedwater before it reaches a

boiler. Sodium sulfite is best introduced continuously at some suitable point in the

feedwater system (the storage section of the feedwater heater or deareator, six

inches below the water line). Chemical residual control is based on the

maintenance of a specific excess of sodium sulfite in the boiler water. The

essential requirement being to maintain in the feedwater at all times slightly more

than enough sodium sulfite to consume all of the dissolved oxygen that slips

through the deareating equipment. Sulfite as a treatment represents the second

line of defense against oxygen corrosion. Primary protection against this type of

attack requires adequate facilities for mechanical deareation of the feed-water

plus a vigorous maintenance program to safe guard against oxygen leakage into

the pre-boiler system.

c) Suspended Solids : Suspended solids are the undissolved matter in water, inc-

luding dirt, silt, vegetation, iron oxides, and any other insoluble matter. Normally

suspended solids are expressed in terms of turbidity. Suspended solids may also

deposit in low velocity areas and create fouling. In line filters, or various types of

pretreatment can be used to lower the suspended solids level. Various polymers

assist in holding solids in suspension. Periodic blowdowns will eliminate

suspended solids.

d) Alkalinity : Alkalinity is the capacity of a water to neutralize acids. Common water

alkalinities consist of bicarbonate, carbonates, hydroxide, phosphate, and

silicate. These alkalinities, especially bicarbonates and carbonates, break down

to form carbon dioxide in steam, which is a major factor in the corrosion on

condensate lines. High alkalinity also causes foaming and carry over in boilers.

Both foaming and carry over cause erratic boiler operation. When foaming occurs

an antifoam should be added or increased. The reason for the high alkalinity

should be determined. It may result from lack of sufficient blow off. Quite often

the source of alkalinity is an overdose of alkaline internal water treatment

chemical.

e) pH: pH is a measure of the degree of acid or base of solution. pH ranges of 8.0-

10.5 will have little influence on the corrosion rate of carbon steel. A low pH can

result in corrosion of metals, while a high pH can result in scale formation or


caustic embrittlement. In order to control boilers and equipment used for the

external treatment of make up water, it is essential that reliable pH

measurements be made. RO/DI water will have a pH of 6.0 - 6.5 and will require

neutralization if used in a carbon steel vessel.

f) Chlorides : If chloride levels are high enough to cause severe corrosion, they can

be controlled by limiting the cycles of concentration and increasing boiler

blowdowns. Corrosion from chlorides can also be controlled by increasing the

amount of corrosion inhibitor or changing to a more effective inhibitor. Reverse

osmosis is another method of pretreatment to reduce chlorides. Chlorides are a

major concern in a stainless steel vessel.

g) Oil : Oil is not a natural constituent of boiler water; still it can frequently enter a

system through leaks in a condenser or other heat exchanger. Oil can also enter

a system through the lubrication of steam driven reciprocating equipment.

Whatever the source, the presence of oil in boiler water is undesirable. Oil can

act as a binder to form scale. In high heat-transfer areas oil can carbonize and

further contribute to the formation of scale and low pH. Foaming is one indication

of oil in boiler water. Its presence can also be confirmed by first shaking a bottle

containing boiler water. If oil is present foam will result. Often oil in boiler water

will originate in the condensate. This contaminated condensate should be

directed to the sewer until the source of the oil is determined and corrective steps

taken.

h) Iron (oxides): Iron in any of its oxide or complex forms is undesirable in boiler

water. Iron in its various forms can originate in the raw water makeup,

condensate return water, or form directly in the boiler as a result of corrosion. It

can concentrate in the boiler and it tends to collect in stagnant areas. If a boiler

is using raw water makeup, iron is almost certain to be a major component of

developing scale or create fouling.

i) Water Hardness : Water hardness is the measure of calcium and magnesium

content as calcium carbonate equivalents. Water hardness is a primary source

of scale in boiler equipment. Hardness is removed by softening.

j) Feedwater : Feedwater is the combination of fresh makeup and returning

condensate that is pumped to the boiler.

k) Condensate : Condensate is condensed steam that is normally low in dissolved

solids. Hence, it does not contribute to the dissolved solid content of the

feedwater. In addition, condensate is very expensive to waste. It's been

chemically treated, heated, pumped, converted to steam, and condensed. This

costs money and when condensate is returned to the boiler, money is saved.


7. Valves

a) Pressure Gauge: the pressure gauge is above the panel box, which is installed

on the right hand of the boiler. A three-way valve is fitted with the pressure

gauge, to assist drain off regularly.

b) Main Steam Valve: the main steam valve is installed on the top of the boiler. It

will be connected with the steam pipe work to all kinds of equipment, which

consume steam. There should be enough outlet for drain off and flush in the pipe

work.

c) Safety Valve: the safety valve is installed on the top of the boiler. Its setting was

finished by the manufacturer before delivery; do not attempt to change the

setting. The function of the safety valve is to avoid pressure in the boiler from

exceeding the design valve. Any equipment connected with the boiler can run

under the boiler pressure. If not, another safety valve must be used to protect it.

CAUTION

The safety valve supplied by the manufacturer can o nly protect the boiler;

it cannot protect any other equipment in the system .

d) Water Level Gauge: the water level gauge is equipped to monitor the boiler water

level. The boiler operator can see the water level inside the boiler from these

gauges. Both of them are connected to a drain line for periodic flushing.

8. Electrical Requirements

a) Connect wiring as shown in the wiring diagram, which is furnished

inside the electrical control panel box.

b) Electrical power available is usually 230/460 volt, 3 phase, 60 HZ (in

USA), 3 phases, 50 HZ (outside USA).

9. Gas Supply

a) Natural gas is the standard gas for the gas boiler. Special

requirements on request- i.e. liquid petroleum gas, town gas.

b) Gas must be supplied at a pressure high enough to overcome the

pressure loss in the burner gas train and furnace while running at full

input. This pressure is different based on the burner used. The

pressure must be checked to make sure it is high enough. If it is too

low, a gas booster must be used in the gas supply system.


c) The gas supply piping to the boiler must be appropriate to local

conditions and must be constructed and installed in compliance

with appropriate Codes and Standards. It should be of sufficient size

to satisfy the pressure and volume flow requirements of the burner

under all firing conditions. Checks should be made to ensure that all

meters and other components are appropriately rated for the maximum

gas flow rate anticipated.

Note

It is essential that a manual isolation valve is fi tted upstream of the gas

control train to allow the burner to be isolated fo r maintenance. The size of

this valve should not be less than that of the burn er control train in order to

avoid any restriction in gas flow.

Warning

It is essential that the installation of the gas pi ping must be undertaken

only by suitably qualified and experienced personnel and in complian ce

with appropriate Codes and Standards. The Fulton Companies can accept

no responsibility for consequential loss, damage or personal injury, which

results from a failure to follow the manual.

Gas Line Sizing Chart

*There is a more exact formula, but you can round off the conversion of CF to BTU by using 1=1000 (for

example 174 CF on the chart would be equal to 174,000 BTU). This will give a more conservative total

estimate.

Pipe

Size

Length of Pipe in Feet

Inches 10 20 30 40 50 60 70 80 90 100

½ 174 119 96 82 73 66 61 56 53 50

¾ 363 249 200 171 152 135 127 118 111 104

1 684 470 377 323 286 259 239 222 206 197

1 ¼ 1404 955 775 663 588 532 490 456 428 404

1 ½ 2103 1445 1161 993 880 795 734 688 641 605

2 4050 2784 2235 1913 1696 1538 1413 1315 1234 1165

2 ½ 6455 4437 3503 3049 2703 2449 2253 2096 1966 1857

3 11,412 7843 6299 5391 4778 4329 3983 3705 3476 3284


Example: From the chart we can see that a ¾” line that is 80’ in length can supply

118,000 BTU/hr.

10. Oil Supply

a) The oil supply piping to the boiler must be appropriate to local conditions

and must be constructed and installed in compliance with appropriate

Codes and Standards. It should be of sufficient size to satisfy the

pressure and volume flow requirements of the burner under all firing

conditions. Checks should be made to ensure that all meters and

other components are appropriately rated for the maximum oil flow

rate anticipated. Galvanized steel pipe should not be used. The supply

piping should include an appropriate filter.

b) A two-pipe system must be used between oil storage tank and the

burner. One for oil supply and one for oil return. A circulating oil pump is

required to deliver fuel oil at 1-3 psig from the storage tank to the burner.

A oil filter must be installed before the oil-circulating pump,

recommend less than 60 Mesh.

c) The final connection to the oil pump inlet should be made using the

flexible pipes supplied with the burner.

d) One gate valve should be installed to the inlet and outlet of the

circulating pump separately. A pressure gauge (0-60psi) should be

added to the outlet.

e) It is important to ensure that the return pipe is not obstructed as this

may result in damage to the pump.

f) In the case of heavy oil (No.4, No.5, and No.6 oil) the piping and oil

storage tank should be insulated, trace heated and thermostatically

controlled.

11. Installation Check Points- Refer to the details in the BURNER section

a) Make sure that all piping connections are complete and tight.

b) Make sure the pressure controls are adjusted properly.

c) Make sure all electrical connections in the control box, the water column,

and elsewhere are secure.

d) Make sure there is adequate boiler room ventilation. Combustion air

contaminates can cause damage to the boiler jacket and burner.

e) Before operating pumps, metering heads and compressors, make

certain that reservoirs are properly filled with the specific lubricant.


Open all necessary oil shut-off valves. Do not run compressors,

pumps, or metering units without oil.

f) Before connecting electrical current to any component, be sure the

supply voltage is the same as that specified on the component

nameplates.

g) Make certain that the operator in charge is properly instructed in the

operation and maintenance procedures.

Note

The pressure vessel must be cleaned before running the boiler after

installation.

12. Cleaning

Steam Piping

a) Steam and water piping systems connected to the boiler may contain

oil, grease, or foreign matter. The impurities must be removed in order

to prevent damage to pressure vessel heating surfaces. On a steam

system, the condensate should be wasted until tests show the

elimination of undesirable impurities. During the period that

condensate is wasted, attention must be given to the treatment of the

raw water used as make-up so that an accumulation of unwanted

materials or corrosion does not occur. For more information, contact

your local authorized boiler representative.

Pressure Vessel

a) The waterside of the pressure vessel must be kept clean from grease, sludge, and

foreign material. Such deposits, if present, will shorten the life of the pressure

vessel, will interfere with efficient operation and functioning of control, of safety

devices, and possibly cause unnecessary and expensive re-work, repairs, and

down-time.

b) The installation and operating conditions that the boiler will be subjected

to should be considered, and cleaning of the waterside of the

pressure vessel should be provided during the course of initial start-

up.

c) The pressure vessel and the steam and return lines, in effect, represent

a closed system. Although the steam and return (condensate) lines

system may have been previously cleaned, it is possible that:


1. Cleaning has been inadequate.

2. Partial or total old system is involved.

3. Conditions may prevent adequate clearing of piping.

d) The pressure vessel waterside should be inspected on a periodic basis.

An inspection will reveal internal conditions and serve as a check

against conditions indicated by chemical analysis of the boiler water.

Inspection should be made three months after initial starting and at

regular 6-, 9-, or 12-month intervals thereafter. The frequency of

further periodic inspections will depend upon the internal conditions

found.

e) If any unwanted conditions are observed, contact your local

authorized boiler representative for recommendations.

f) Any sludge, mud or sediment found will need to be flushed out. If

excessive mud or sludge is noticed during the blowdown the scheduling

or frequency of blowdown may need to be revised. The need for periodic

draining or washout will also be indicated.

g) Any oil or grease present on the heating surfaces should be removed

promptly by a boil-out with an alkaline detergent solution.

Note

Temperatures of initial fill of water for hydrostat ic tests, Boil-out, or for

normal operation should be as stated in the ASME Boiler Code.

Caution

Do not store halogenated hydrocarbons in or near th e boiler room. In general,

ensure that the boiler area is in conformance with established boiler room

requirements. Review national and local codes.

h) As a final checkpoint, again...Water Treatment! We cannot emphasize enough the

importance of proper water treatment: Water analysis should be made by a

competent water treatment professional and their recommendations should be

followed.

13. Boil-out of New Unit

a) The internal surfaces of a newly installed boiler may have oil, grease or other

protective coatings used in manufacturing. Such coatings must be removed


because they lower the heat transfer rate and could cause over-heating of a tube.

Before boiling out procedures may begin, the burner should be ready for firing. The

operator must be familiar with the procedure outlined under burner operation.

Warning

Use of a suitable facemask, goggles, rubber gloves, and protective garments is strongly recommended when handing or mixing caustic chemicals. Do not permit the dry material or the concentrated solution to come in contact with skin or clothing. Failure to f ollow these instructions could result in serious personal injury or death.

b) The suggested general procedure for clearing a boiler is as follows:

i. Have sufficient cleaning material on hand to complete the job.

ii. When dissolving chemicals, the following procedure is suggested.

Warm water should be put into a suitable container. Slowly

introduce the dry chemical into the water, stirring it at all times

until the chemical is completely dissolved. Add the chemical slowly

and in small amounts to prevent excessive heat and turbulence.

iii. Isolate the boiler from the system by shutting off the main steam

valve.

iv. Remove the steam safety valve.

v. Water relief valves and steam safety valves must be removed

before adding the boil-out solution so that neither it nor the grease

which it may carry will contaminate the valves. Use care in

removing and reinstalling the valves.

vi. All valves in the piping leading to or from the system must be

closed to prevent the cleaning solution from getting into the

system

vii. Replace the steam safety valve.

viii. Fill the boiler with water. Water level is about center in the water

gauge glass.

ix. Generate 5 PSI (1.054 kg/cm2) of steam and shut off the boiler.

Allow this hot solution to remain in the boiler for 10 minutes.

x. Allow the boiler to cool to <140F.

xi. Drain and flush the boiler twice with fresh water.

xii. To remove all the oil and dirt from the main steam and the

condensate return lines, allow the returns to go into a floor drain or

a safe discharge point for the first few days of operation.


Warning

Be sure to drain the hot water to a safe point of d ischarge to avoid scalding.

Failure to follow these instructions could result i n serious personal injury or

death.

xiii. Remove hand-hole plates.

xiv. Inspect the surfaces. If they are not clean, repeat the boil out.

xv. After closing the hand-holes and reinstalling the safety or relief

valves, fill the boiler and fire it until the water is heated to at least

180oF to drive off any dissolved gases, which might otherwise

corrode the material.

xvi. The above procedure may be omitted in the case of a unit

previously used or known to be internally clean. However,

consideration must be given to the possibility of contaminating

materials entering the boiler from the system.

xvii. On a steam system, the condensate should be wasted until tests

show the elimination of undesirable impurities. During the period

that condensate is wasted, be sure make-up water is treated to

prevent an accumulation of unwanted materials or corrosion.


Section 4


Section 4 – Controls & Burner

The following brief description of the fittings and controls used on the FB-S boiler is intended

to provide the operator with a basic understanding of the operating principles, which is essential for

the continued efficient use of the boiler.

1. Boiler Control Panel

a) Boiler controls and indicators are housed in a control panel mounted on the

side of the boiler. These controls are as follows:

i. Power Isolator Switch - control panel power supply ON/OFF switch,

mounted on the panel door.

ii. Power On Indicator - indicates that the door isolator is in the ON position

and the panel is electrically live.

Warning

The power on the indicator is derived from one phas e. It is possible for

that the Power On Indicator supply phase to be down , leaving the other

two phases live. Always isolate the supply before working on the panel.

Motor Fuses

Fan Motor Starter

Water Level Relays

Flame Programmer

Various Relays


b) Low Water Indicator

i. This lamp will be illuminated and an alarm sounded when the water level,

as sensed by an internal probe, in the boiler falls to the 1st low water

level. The burner will shut down and the alarm will continue to sound until

the water level is restored to a safe working level. The alarm will then

cancel, the indicator lamp will extinguish and the burner will automatically

restart.

c) Low Water Alarm/Reset Switch

i. Sounds and alarm on switch on, press to reset. If the level of water in the

boiler falls below the second pre-set limit, as sensed by a second low

water internal probe, during boiler operation. The 2nd Low Water

Alarm/Reset Switch will illuminate, the alarm will sound and the burner

will shut down. The water level must be restored before the alarm can be

cancelled by pressing the switch.

d) High Water Indicator

i. This lamp will illuminate and alarm sound when the water level reaches a

pre-determined high level, as sensed by an internal probe. The feed pump

will stop. When the water level falls to the normal working level, the

indicator lamp will extinguish and the alarm cancel.

Note

The Burner ON/OFF/Reset switch should be in the OFF position during the filling process.

The Pump Hand/Off/Auto Switch should be in the PUMP Auto position, except when manually filling the boiler (Hand posit ion).

The 2nd Low Water Alarm can only be cancelled if the boile r water level is

above the 2 nd Low Water Level. If the alarm cannot be cancelled, allow the

feed water pump to restore the water level to the n ormal working level

(approximately mid-way up the sight glass) and the reset the alarm.

e) Low Water Safety Relays and Feedwater Pump Relays

i. These relays operate in conjunction with probes suspended in the

boiler shell (or externally mounted floater pressure differential

transmitters) to automatically maintain the water level in the boiler

between set limits. If the water should fall to an unsafe level, the burner is

cut out and an alarm is sounded. The probes are located in two,


100mm diameter standpipes mounted on top of the boiler center line

towards the front of the boiler. A standard boiler is fitted with Feedwater

pump On/Off, 1st Low Water, 2nd Low Water and High Water probes.

Note

If the Level Control System is a float type or pres sure differential transmitter,

then refer to specific spec sheets located in this manual.

f) Steam Pressure Controls

i. Three steam pressure controls are mounted on the side of the boiler near

the control panel. These are as follows:

a. Operating Control Pressure On/Off Switch. Controls the

on/off cycle of the boiler, switching the burner off when

the desired steam pressure is reached and switching it

on when steam pressure falls.

b. High Limit Switch. Should the Control Pressure Switch

fail, the steam pressure will raise above

the pre-set limit causing the High Limit Switch (set a

least 0.5 {3-4 psig} bar higher than the Control

Pressure Switch) to switch off and lock out the burner. A

High Limit Indicator will illuminate and an alarm will sound.

c. Modulating Pressure Switch. Switches the burner from high

to low flame and vice-versa as steam pressure/water temp

increases or decreases from setpoint.

2nd LWCO

Pump On

1st LWCO

Pump Off

High Water


Note

Boiler may be supplied with PID type pressure contr ols in lieu of on/off and

high/low pressure switches.

g) Burner Programmer

i. Is located in the center of the control panel. Acts in conjunction with a

sensing device to ‘supervise’ the ignition sequence, prove the flame is

satisfactory and finally ‘monitor’ the established flame.

Should any fault occur, either during the ignition sequence or during

normal running, the programmer will immediately go to ‘lock-out’ and both

main and pilot gas/oil valves will shut to isolate the fuel line

to the burner. Lockouts include high steam pressure, low water, high/low

gas pressure and flame failure.

h) Flame Failure Indicator

i. Indicates the burner combustion control relay, detects a flame failure

condition.

2. Burner

Fulton Boiler FB-S model can mount with gas burner, oil burner or dual fuel burner

on customer’s request. See specific Burner Manual fro details.

Oil Burner

The fuel for the oil burner is from No.2 to No. 6 oil. The standard light oil burner for

a Fulton boiler is No.2 oil. The heavy oil burner can be used for No.4 to No.6

oil.

Modulating Control

Operating Limit

High Limit w/ Manual Reset


a) Air Pressure Switch

i. Mounted on the burner, this switch is operated by the pressure of air

entering the burner though the throat of the scroll. Lack of combustion air,

or insufficient air pressure, will stop the switch completing the circuit,

preventing the burner from operating.

b) Air Damper Servomotor

i. The combustion air control system including air damper and a

servomotor. The servomotor is mounted on the burner and directly

coupled to the air damper blade. this system monitors and controls the

combustion air entering the burner on the requirement of the boiler heating

during operating. A fully closed position is provided to prevent air flowing

through the appliance when the burner is not in operation.

c) The Inner Assembly

i. Consist of flame tube, diffuse, oil nozzle, ignition electrode and so on.

d) Oil Nozzle

i. The oil nozzles are held in a nozzle block located within the flame

tube. The nozzles are pre-sized by the manufacture according with the

heat inputs required and the available operating pressure. When

replacing the nozzles, they must be the same capacity as the original.

Note

When fitting nozzles to the heavy oil burners the n ozzle filters must be removed. In calculating the correct size of nozzles to be fi tted, refer to the specific burner manual.

Possible Burner Options for FBS


e) Oil Pre-heater Tank (for heavy oil burners)

i. The oil preheater tank is mounted on the heavy oil burner ahead of the fan

housing. Its function is to preheat the oil to correct temperature. The unit is

equipped with three thermostats, ‘low temperature’ ‘operating’ and ‘limit’. A

thermometer and hot oil filter are mounted together as one unit on the

top left-hand side of the preheater tank viewed from the rear of the

burner.

f) Air Pressure Switch

i. Each of the gas burners is mounted on an Air Pressure Switch on the

burner scroll. Lack of combustion air, or insufficient air pressure, will stop

the switch completing the circuit, preventing the burner from operating.

g) Air Control

i. The Air Control System of the gas burners is similar to that of the oil

burners. The servomotor is mounted on the rear of the air inlet of the

burner and directly coupled to the air damper blade. This system

monitors and controls the combustion air entering the burner on

the requirement of the boiler heating during operating. The servomotor has

been adjusted by the manufacturer before the boiler delivery, so normally

the customer needn’t set it again.

h) Gas Train Assembly

i. Consist of pilot and main supply line, each line having a manual cock, a

governor, solenoid operated valves and two-air pressure switch (high and

low). The governors maintain a constant pressure of fuel entering the

burner and are adjustable. The solenoid valves are electronically controlled

by the burner programmer. For specific details, consult the burner

manufacturer’s instruction manual.


i) Valve Proving System

i. A valve proving system, as show schematically below, is standard on the

FB-S Boilers. When the boiler operating sequence is initiated, the burner

control box energizes the proving system, which then carries out the

following checks.

a. Valves V1, V2 and V3 are initially closed. The proving

system then opens V3 and then closes it after 2 seconds.

b. V1, V2 and V3 remain closed for 23 seconds while the

minimum side of the gas pressure switch (PS) checks

for an increase in pressure. If no crease occurs there is

no leakage past V1 and the sequence continues.

c. V1 is opened for 2 seconds and then closed. V1, V2

and V3 again remain closed for 23 seconds while the

maximum side of the gas pressure switch checks for

a decrease in pressure. If no decrease occurs there is

no leakage past V2 or V3 and the burner operating

sequence will continue.

j) Flame Monitor

i. An ultraviolet cell is fitted as standard on all burners. It monitors the status

of the flame, any failure will cause the burner to shut down.


Section 5


Section 5 – Operation Boiler starting

STOP! Make sure you have read any followed all previous safety information.

Check with local authorities where approval for start-up is required. In some

localities, final inspection of services may be required.

In general, ensure that the boiler area is in conformance with established boiler

room requirement. Review national and local codes.

Carry out the following procedure on the initial start up of the boiler and on every

subsequent occasion when restarting the boiler after a shut down.

1. Filling the Boiler

a) Ensure the following valves are OPEN

i. Main Steam Valve

ii. Steam pressure gauge isolating valve

iii. All valves in the water feed line

iv. Water gauge isolating valves

v. Air release valves

b) Ensure the following valves are SHUT

i. Surface and bottom blowdown valves

ii. Water gauge blowdown valves

iii. All valves in the gas/oil train to the burner

c) Ensure that the Burner On/Off/Reset Switch is set to OFF

d) Ensure that the Pump On/Off switch is in the PUMP OFF position, and that the

Hand/Off/Auto Switch is in the Off position.

e) Place the Pump On/Off Switch to the PUMP ON position, or Hand/Off/Auto in the

Auto position.

f) The feed pump should start and fill the boiler to the pump off level and then switch

off.


Note

If the 2 nd Low Water and High Pressure Alarm/Reset switch ill uminate and

the alarms sound, check that the burner mounted Bur ner On/Off/Reset

Switch is in the OFF position, and then reset both alarms by pressing the

switches

Note

It may be necessary to vent the feed water pump by bleeding air from the

plug mounted in the top casting below the pump moto r to pump body

connection

2. Starting the Burner From Cold

a) Fill the boiler as described in Section 1.

b) SHUT the main steam valve.

c) Open all the valves in the gas train/oil supply. It is assured that the fuel supply

lines have been purged prior to attempting to start the boiler/burner.

d) Switch the Burner On/Off/Reset Switch to the ON position. The 2nd Low Water and

High Pressure Alarm/Reset switches will illuminate and alarms will sound due to

the power restoration interlock.

e) Reset the alarm by pressing both switches. If the 2nd Low Water alarm cannot be

cancelled, check the water level in the sight glass.

f) The burner motor will start and, after going through post purge/ pre purge interlock

checks, should fire after approximately 45 seconds.

Note

Before leaving the boiler unattended, the daily ope rating tests should be

carried out to check the functions of all the safet y interlocks. For more

detailed information on the burner firing sequence consult the burner

manufacture’s Operation and Maintenance instruction s.

Practical Considerations

When starting up the boiler, it is prudent to minimize the thermal and mechanical stress

caused by differential expansion of various parts of the boiler as they reach working

temperature. The temperature of the shell is determined by the contained water/steam


temperature and by the heat transfer rate and gas temperature. The tube temperature lies

between the shell and furnace temperature, but is nearer the shell temperature. Since all

these components are virtually the same length, they expend longitudinally by different

amounts causing mechanical and thermal stress. Whilst this is catered for in mechanical

design of the pressure vessel, the life expectancy of the boiler can be affected if the boiler

is frequently heated to quickly from cold. When starting from cold the furnace approaches

its design temperature shortly after start-up, whereas the tube and shell temperatures are

delayed by the time taken to bring the contained water up to temperature. As a result, the

thermal expansion is at its greatest. Additionally, the temperature gradient which exists

between the bottom and the top of the boiler is exaggerated. This can be

reduced by blowing the boiler down during the heat-up period. In practical terms, the ideal

solution would be to gradually raise the temperature and pressure in the boiler

progressively by firing the boiler on low fire for a few minutes and leaving it to ‘soak’ (e.g.

allowing the temperatures in the boiler and water to even out by diffusion) for 20 to 30

minutes, blowing down the boiler, firing the boiler again for a little longer and soaking for

less, and so on. If the boiler has been fired the day before, the large thermal mass in the

boiler will maintain the internal temperature to a point that the boiler can be simple switched

on (preferably on low fire) and then left to reach working temperature/pressure. The life

expectancy of the boiler and door insulation, ignoring other factors, is proportional to the

number of the thermal/mechanical cycles that the boiler undergoes from cold/zero pressure

to working temperature and pressure. A boiler that is continually maintained at working

pressure will last longer than one that is constantly heated and cooled.

Service Inspection of Weld Joints

The frequency of the safety requirement for in service inspection of the main welded joints

of the boiler is calculated by the number of cycles since the last inspection. Boilers running

twenty four hours a day require the shell and furnace end plate welds to be inspected at

intervals specified by local boiler codes. Boilers that are continually heated and cooled

require more frequent inspection. The purpose of the in-service weld inspections is to check

for:

i. Buried defects during manufacture that are outside acceptable limits.

Because the boiler was 100% tested during manufacture none should be

found, and upon proof of 100% manufacturer testing these tests may be

waived at the discretion of the ‘competent person’.

ii. Cracks propagating from region of the toe of the fillet weld on the shell to

the tube plate weld, resulting from fatigue or corrosion fatigue cracking.


These cracks would not be there after manufacture but can develop in

service, they are caused by stress due to a combination of pressure loads,

differential expansion, local temperature gradients, oxygen impurities in the

boiler water/steam and inadequate PH (water chemistry) control.

Differential thermal expansion and local temperature gradients all result

from continuous pressure/temperature cycling and heating from cold too

quickly. Water treatment and in particular

oxygen corrosion are covered in Section 3. The importance of correct

water treatment cannot be over emphasized.

To Achieve Long Trouble-Free Boiler Life:

i. Maintain the boiler at working pressure as long as possible, minimize

cycling.

ii. When heating from cold do so slowly.

iii. Maintain water treatment within the prescribed limits at all times, blowdown

frequently.

3. Daily Operating Tests

Caution

If any of the following tests fail to function as d escribed, shut down the boiler

immediately and consult the factory.

With the burner firing, carry out the following tes ts:

Note

Ensure the correct water level is maintained during pressure build up. If

any part of the equipment is not operating correctly, the fault sho uld be

investigated before the boiler is used. Ensure all blowdown piping is safe and

discharged to a blowdown receptacle.

a) Flame Sensor (UV Photo Cell) Check

i. Remove the burner UV photocell from its plug-in connection (on the side of

the burner) and cover the detection window to exclude all light. The

burner control should immediately (2-3 seconds gas, 5 seconds oil) go

to a lockout/flame failure condition and will require manual resetting.

Clean the UV photocell with soft cloth before replacing it.


b) Pump Check

i. Lower the water level in the boiler, either by evaporation or by opening

the main blowdown valve with the key provided.

ii. Observe the water level in the water level gauges and, as the water

level falls, check that the feed water pump starts.

iii. SHUT the main blowdown valve if opened, and ensure that the feed

water pump continues to fill the boiler to the correct level then switch

off.

c) 1st Low Water Check

i. Turn the Pump On/Off Switch on the boiler control panel to the PUMP

OFF position.

ii. Lower the water level in the boiler, either by evaporation or by opening

the main blowdown valve with the key provided.

iii. Observe the water level in the water level gauges and check that, as

the water level reached the low water position:

a. The 1st Low Water alarm sounds

b. The 1st Low Water indicator lamp illuminates

c. The burner stops firing

iv. SHUT the main blowdown valve if opened, and turn the Pump On/ Off

Switch to the PUMP ON position, Check that:

a. The feed water pump starts

b. The water level in the boiler is restored to the normal

working position

c. The 1st Low Water indicator lamp extinguishes and the

alarm cancels

d. The burner automatic start sequence commences

d) 2nd Low Water Check

i. Repeat the procedure described in above section but allow the water

level to continue to fall, either by evaporation or maintaining the main

blowdown valve open. Before the level falls below the level of the water

level gauge, check that the 2nd Low Water Alarm/Reset Switch

illuminates, the alarm sounds and the burner shuts down.

ii. SHUT the main blowdown valve (if opened).

iii. Set the Pump On/ Off Switch to the PUMP ON position.

iv. Check that:

a. The feed water pump starts, restores the water level to a

safe working level, then stops


b. The 1st Low Water alarm cancels

c. The 1st Low Water indicator lamp extinguishes but the

burner does not start

d. The 2nd Low Water alarm continues to sound

e. The 2nd Low Water Alarm/Reset Switch remains

illuminated

v. Press the 2nd Low Water Level Alarm/Reset Switch.

vi. Check that:

a. The 2nd Low Water alarm cancels

b. The 2nd Low Water Alarm/Reset Switch extinguishes

c. The automatic burner firing sequence commences

The Low Water Cutoff tests can be accomplished by isolating the feed pump using the

pump ON/OFF switch on the boiler control panel while the boiler is operating. Allow the

water level to fall by evaporating steam to the system.

Once the 1st Low Water Level Alarm is activated the water level can be lowered to the 2nd

Low Water Level by using the main blowdown valve.

When the 2nd Low Water Alarm sounds CLOSE the blowdown valve, turn the feed water

Pump On/Off switch to PUMP ON.

Once the 1st Low Water Level cancels the burner should remain off, but the 2nd Low Water

Alarm should continue to sound, reset the 2nd Low Water Alarm. The burner should start

and the pump restores the water level to normal and stop.

4. Blowdown Procedure

In order to keep the boiler and water level gauge pipe work clear and free from sludge and

scale build-up, regular blowdown should be carried out.

Boiler Blowdown

a) Fully OPEN the fast opening blowdown valve, for a minimum of 5-10 seconds, see

note.

b) Regulate the blowdown flow using the common slow opening Y-type valve.


Note

As well as removing sludge from the boiler, a secon d and equally

important function is to maintain the TDS (totally dissolved solids) level t o

within the required limits. The amount of blowdown, and hence time

required, it dependent on the amount of TDS in the raw water supply, the

percentage condensate return, water treatment chemi cals added and the

number of the hours a day operation. In order to es tablish the required

blowdown rate, consult your water treatment specialist who will

recommend a water treatment program in terms of app ropriate

chemicals and the required blowdown rate, which tak es these factors

into account.

Water Level Gauge Blowdown

a) Blowdown the water level gauge set by opening the gauge blowdown valve A and

closing the top and bottom gauge valves B and C in sequence.

b) On completion of the blowdown procedures, ensure all isolation valves are open,

and all blowdown valves are SHUT (all handles vertical).

5. To Shut Down the Burner

Short Term (hours)

a) Turn the burner On/Off/Reset Switch on the Burner Control Panel to OFF.

b) The burner will stop firing, post-purge and then stop.

Flame Programmer

Pressure Controller Pressure Switches

Level Probes

Steam Stop Valve

Surface Blowdown Connection

Level Controller Feedwater Connection


Medium Term (days)

a) Turn the Burner On/Off/Reset Switch on the Burner Control Panel to OFF.

b) The burner will stop firing, post-purge and then stop.

c) SHUT the main steam valve.

d) SHUT the water feed valve.

e) Turn the power isolator On/Off switch on the Boiler Control Panel to OFF.

Note: Ensure the boiler water treatment levels for dissolved oxygen are within specified

limits.

Long Term (weeks)

To store the boiler in a corrosion-free situation there are three practical solutions as follows:

a) Fully flood the boiler to exclude as much air as possible.

b) Drain the boiler completely.

c) Remove all hand hole and manhole doors.

d) Open all gas/oil-side access doors (refer to the maintenance section)

e) As (b) but also introduce a form of convection heating to the gas/oil and water side.

A very effective solution is to install a string of outdoor-type waterproof light bulbs

distributed throughout the boiler.

6. Evaporation Test

This test may be required by your insurance inspector as part of the annual inspection.

a) With the burner running, switch off the boiler feed pump and allow the water level in

the boiler to lower by evaporation.

b) When the water level reaches the 1st Low Water position an alarm will sound, the 1st

Low Water indicator lamp will illuminate and the burner will stop.

c) Allow the evaporation process to continue until the 2nd Low Water alarm sounds

and the 2nd Low Water Alarm/Switch illuminate.

d) Switch the feed pump to the PUMP & BURNER ON position.

e) The water level will be restored to normal working level, the 1st Low Water

indicator lamp will extinguish and the alarm will cancel.

f) Press the 2nd Low Water Alarm/Reset switch.

g) The 2nd Low Water Alarm/Reset switch will extinguish, the alarm will cancel and the

burner will start.

Note

Because the burner shuts down during this test it i s possible that the steam

load will rapidly decrease the pressure in the boil er causing a premature 2 nd


Low Water alarm. This is normal and typical of ‘priming’ where a boiler tries

to maintain an overload condition resulting in unstable water conditions.

7. Fault Finding

Before calling the Fulton Service Department, check the following:

a) Gas isolating valve(s) OPEN (gas and dual fuel burners).

b) Oil isolating valve(s) OPEN (gas and dual fuel burners).

c) Oil storage tank contains an adequate level of fuel.

d) Oil filer(s) are not blocked.

e) Water feed line from feed tank/hotwell is OPEN.

f) Water feed isolating valve on boiler is OPEN.

g) All blowdown valves are SHUT.

h) Fuses or MCBs in the main supply are not tripped.

i) Thermal overload on the pump motor is not tripped.

j) Thermal overload on the burner motor is not tripped.

k) Normal water level is visible in the water level gauges.

l) Feed pump is primed and not air locked.

m) Front door proof of closure microswitch is closed.

Before calling the Fulton Service Department, have the following information available:

a) The model and size of the boiler.

b) The boiler serial number.

c) The model and type of burner fitted.

Note

A very common problem is that when a boiler cools d own, the steam in

the steam space condenses and gradually forms a vacuum. If the feed water

line is open, the boiler will draw in water in an a ttempt to equalize the

pressure. The appearance in the water level gauges is the same if they are

empty or fully flooded. If the sight glasses appear empty, but the water level

control alarm(s) have not sounded, it is highly pro bable that the boiler is

flooded. Allow air into the system and drop the wat er to the normal operating

level by opening a blowdown valve. Installing a vac uum breaker on the boiler

or steam header will not allow a vacuum condition t o occur as a boiler cools

down.


Fault Finding Table

Problem Solution

Burner does not start

1. No voltage at program relay power input terminals.

a) Main disconnect switch open.

b) Blown control circuit fuse.

c) Loose or broken electrical connection.

2. Program relay safety switch requires resetting.

3. Limit of circuit not completed-no voltage at end of

limit circuit program relay terminal.

a) Pressure of temperature is above setting of

operation control.

b) Water below required level.

c) Fuel pressure must be within setting of low

pressure and light pressure switch.

d) Check burner air proving switch and high fire

limit switch.

e) Heavy oil fired unit-oil temperature below

minimum setting.

4. Fuel valve interlock circuit not completed.

No Ignition

1. Lack of spark

a) Electrode grounded or porcelain cracked.

b) Improve electrode setting.

c) Loose terminal on ignition cable.

d) Inoperative ignition transformer

e) Insufficient at pilot ignition circuit terminal.

2. Spark but not flame

a) Lack of fuel-no gas pressure, closed valve,

empty tank, etc.

3. Low fire switch open in low fire proving circuit.

Damper motor not closed, defective switch.

4. Running interlock circuit not completed.

a) Combustion or atomizing air proving switch

defective or not properly set.

b) Motor starter interlock contact not closed.

5. Flame detector defective, sight tube obstructed or

lens dirty.

6. Check the programmer controller.


Pilot flame, no main flame

1. Insufficient pilot flame.

2. Gas fired unit

a) Manual gas cock closed.

b) Main gas valve inoperative.

c) Gas pressure regulator inoperative.

3. Oil fired unit

a) Oil supply cut off by obstruction, closed

valve, or loss of suction.

b) Supply pump inoperative.

c) No fuel.

d) Main oil valve inoperative.

e) Check oil nozzle, gun and lines.

4. Flame detector defective, sight tube obstructed or

lens dirty.

5. Insufficient or no voltage at main fuel valve circuit

terminal.

Burner stays in low fire

1. Pressure or temperature above modulating control

setting.

2. Manual-automatic switch in wrong position.

3. Inoperative modulating motor.

Shutdown occurs during firing

1. Loss or stoppage of fuel supply.

2. Defective fuel valve; loose electrical connection.

3. Flame detector weak or defective.

4. Scanner lens dirty or sight tube obstructed.

5. If the programmer lockout switch has not tripped,

check the limit circuit for an opened safety control.

6. If the programmer lockout switch has been tripped;

a) Check fuel lines and valves.

b) Check flame detector.

c) Check for open circuit in running interlock

circuit.

d) The flame failure light is energized by ignition

failure, main flame failure, inadequate flame

signal, or open control in the running interlock

circuit.

7. Interlock device inoperative or defective.

8. Air in the oil lines. Bleed lines.


Boiler will not maintain pressure

1. Check oil supply in the supply tank. Check for

clogged nozzle. Clean or replace it. Check oil filter and

replace if necessary.

2. Check gas supply.

3. The flue is too dirty. Clean it.

4. Check the steam pressure switch, reset it if

necessary.

5. Steam is overloaded, reduce it.

Water pump does not start or stop manually

1. Check the connection of water probe.

2. Check and clean the water probe.

3. Check the water level relay, if necessary replace it.

Low water alarm/burner shut off will not act in tim e

1. Check for tightness and clean the connections.

2. Clean or replace the dirty probes.

3. Replace the water level relay.

4. Check the tightness of the earth connection.

Starting the boiler, the high limit steam pressure

limit is illuminated and the burner stops

1. Boiler is completely filled with water, blow down the

boiler to normal water level.

2. On/Off pressure switch has failed; check the reading

on the pressure gauge.


Section 6


Section 6 – Maintenance 1. General Maintenance

To ensure the continuing efficiency of the boiler, regularly carry out regular

routine maintenance procedures as detailed below.

IMPORTANT: If any fault is found during these proce dures, shut down the

boiler immediately and consult The Fulton Companies .

Note

It is essential that regular checks are made to ens ure scale build-up is not

taking place within the boiler. Such checks will en sure that water treatment

being applied to the boiler water feed is effective .

The lower hand hole doors should be removed after o ne month and the

interior of the boiler thoroughly examined. If scale or sludge build-up is

observed, a water treatment specialist should be consulted.

Subsequent interior examinations should be carried out on a regular basis

until satisfactory conditions are obtained. Thereafter, inspections should be

carried out at six monthly intervals.

IMPORTANT: New gaskets must be fitted every time a hand hole door is

removed, refer to Section 5 for fitting procedures.


2. Weekly Maintenance

Warning

All steam pipe work, valves and fittings will be ve ry hot. Do not operate

the safety valve without protection.

Check the hand holes and man holes for signs of leakage. This is particularly

important when the boiler is started from new or when gaskets have been

replaced (refer to the Section for fitting procedures for new gaskets). Corrective

action taken as soon as a leak occurs can prevent costly repairs later.

Check for signs of leaks on all valves and fittings and take the appropriate action.

Test all the boiler water level functions by evaporation, e.g. switch off the

boiler feed pump-see Starting the Burner.

Carry out routine maintenance checks on the burner as recommended by

the manufacturer’s Installation and Maintenance instructions.

Check the flame failure controls by removing the burner flame sensor from its

plug-in connection on the side of the burner and covering the detection window

to exclude all light. The burner control should immediately go to a lockout flame

failure condition and will require manual resetting. Clean the flame sensor before

replacing it.


3. Six Month Maintenance

Warning

The boiler must be completely cold before carrying out any of the following

procedures.

a) Ensure that the following valves are SHUT:

i. The main steam stop valve

ii. The feed water isolating valve

iii. The fuel (gas/oil) valves

b) Ensure that the power supply to the boiler is switched OFF.

Caution

The boiler and attaching parts will retain heat lon g after the boiler has been

shut down. Always use protective clothes and extrem e caution when

working on a hot boiler.

c) Empty the boiler. It will be necessary to allow air into the boiler before it will drain via

the main blowdown valve.

d) Remove the hand hole and manhole doors and thoroughly inspect the internal

surfaces of the boiler, paying particular attention to the junction of the tubes

with the front tube plate and the tubes for signs of pitting. Any deposits should

be removed and your water treatment specialist consulted. Ensure there are no

accumulated deposits of sludge in the bottom of the boiler.

e) Remove the feed water dispenser, inspect and clean.

f) Replace the man hole and hand hole door gaskets, refer to Section FITTING

NEW GASKET for fitting procedures

g) Open the boiler front access door with the burner mounted on it as described

below. It will be necessary to disconnect the gas supply from the gas train and oil

supply from the oil lines to allow the door to swing open.

h) Remove water column plug at cross section and clean nipple to boiler.


i) Remove the rear smoke box access doors.

j) Brush through the tubes to remove any deposits from the products of combustion.

k) Using a wire brush, clean the internal surfaces of the furnace and the face of the

front tube plate. Pay particular attention to the tube ligaments (the spaces

between adjacent tubes).

l) Inspect the tube ends for any signs of splitting or burning. These are symptoms of

gas re-burning in the tube ends as a result of poor combustion, e.g. carbon

monoxide carry-over. If the tube ends exhibit these signs, consult the Fulton Service

Department.

m) Clean out the rear smoke boxes to remove the deposits brushed through from the

tubes.

Important

Ensure that the rear smoke box drain connections ar e clean and free from

deposits. This is particularly important on oil fired boilers because of the

acidic nature of the condensate formed.

n) Inspect the door seal for signs of wear and replace if necessary. The first indication

of a worn door seal would be evident by signs of leakage around the external

periphery of the door.

Warning

When handling ceramic fiber always follow the local regulations regarding

such materials, including the use of breathing appa ratus, suitable body

protection and protective gloves.

o) Examine the internal surface of the door lining for defects. Small repairs may be

carried out by cutting out the defective area and replacing with new fiber, ensure

the correct adhesive is used.

p) Examine the end of the burner blast tube where it extends through the door into the

furnace. Clean off any deposits, paying particular attention to the internal lip where

deposits can cause irregular flame patterns.

q) Inspect the rear smoke box door seals for deterioration and replace if necessary.

r) Close the hinged front access door by reversing the opening procedure.

s) Re-connect the gas/oil connections.

t) ) Drain and flush the feed water/ hotwell tank, clean any filters and the strainer in

the feedline before the pump.

u) Drain and flush out the blowdown separator.


v) Carry out routine maintenances to the burner as detailed in the manufacturers’

installation and maintenance instructions.

Note

Depending upon the mode of operation, it may be fou nd that the six

monthly interval can be extended, possibly to an annual service. It is

strongly recommended, however, that the interval should be 6 months

from initial start up until such times as a ‘patter n of use’ and the condition of

the boiler after a typical 6 months can be establis hed.

4. Annual Maintenance

It is normal practice to carry out an annual service during which your insurance

surveyor would attend to carry out the statutory inspection. The scope of a full

insurance strip-down is such that it should only be attempted by persons

competent to do so who have had the necessary training, and have the

required test equipment. Fulton Boiler Works can offer this service if required.

The engineering surveyor may require the removal of the ceramic fiber

insulation around the periphery of the front tube plate to facilitate inspection of

the shell to tube plate weld. The standard Fulton service kit includes

replacement ceramic fiber log material which must be glued in place with the

adhesive supplied. It is vital the material is fitted ensuring the ends of the fiber face

into the centre of the boiler.

5. Fitting New Gasket

General

Incorrect (Overtightened)

Correct Installation


Caution

TOPOG-E gasket have a finite life after installatio n and must be

renewed annually. It is important that the instructions given in this secti on

are adhered to.

The boilers are fitted with TOPOG-E gaskets in all the inspection holes of the

boiler. These gaskets work very well and millions have been safely used over the

last 30 years, however, it is absolutely essential to observe a few simple rules in

order to get the best performance from your installation. Elastomeric Vulcanizates,

which form the basis of TOPOG-E gaskets, undergo degradation from many

sources including heat, oxygen, stress, and overdosing from certain types of water

treatment. This takes the form of material oxidation, hardening/embrittlement and

cracking which may result in gasket failure. Steps must be taken to minimize the

effects of such attacks.

Water treatment and oxygen attack can be combated by ensuring that the gasket is

aligned correctly so that only the extreme edges of the gasket are exposed. If a

new gasket leaks after fitting this is almost certainly due to incorrect sealing or

alignment. Incorrect sealing or misalignment will reduce the life of the gasket and

cause problems later.

Under stress can be avoided by tightening just sufficiently to stop any leakage

when fitting cold and before firing the boiler. Fire the boiler and then gradually

warm the boiler up, allowing the increasing steam pressure to take over and

complete the seal. The will allow the gasket material to contract naturally and

follow the topography of the mating surfaces. The securing nut can then broken

when the boiler is cold and under negative pressure.

Gentle warming of the boiler on initial firing after maintenance will also help to

ensure that the rubber ‘cures to shape’. If the rubber post-cures, the elastic

memory will be destroyed and any initial over-tightening will cause the gasket

to become hardened and embrittled, leading to cracks and eventual failure.

Fitting Instructions

Blowdown the boiler completely and examine all inspection holes in the boiler. If

any leakage is evident, proceed as follows:

a) Remove the old gasket and thoroughly clean the mating faces of the cover plate

and boiler ring.


b) Pace the new Topog-E gasket on the cover plate, ensure the gasket is the

correct size and is seating flat against the plate. Do not use any grease, lubricant

or adhesive. If the new gasket is not seated properly before the plate is

tightened, the gasket may be pinched causing a failure when the pressure builds

up.

c) Position the cover plate in the boiler ring, ensuring that the plate is correctly

centered. An off-centre cover plate can concentrate forces on the gasket and cut it

in two. The cover plate may also drag on the boiler hole ring and fail to seal as the

pressure rises. Set the crabs further quarter of the turn using a spanner. DO NOT

OVERTIGHTEN.

Note

Ensure the gasket is aligned correctly so that only the extreme edges are

exposed to water treatment or oxygen attack. If the gasket is misaligned,

over tightening to seal a leak will not prevent sub sequent leakage at a later

date.

d) Gradually warm up the boiler, allowing steam pressure to make the seal. If the

gasket leaks during pressure build up, tighten the securing nuts sufficiently

only to stop the leakage. It is important to keep the nuts correctly tightened

thereafter, this prevents the vacuum developed by cooling on shutdown from

feeding and draining the boiler.

Note

New gasket fitted to inspection holes located along the bottom of the boiler

are more difficult to install without leaking. Smal l particles of the scale or

sand tend to run down on the mating surfaces after cleaning but prior to

assembling. This condition is likely to have occurr ed if excess tightening

is required to stop a leak before warming the boile r. In this event, the best

course of action is to drain the boiler and repeat the gasket fitting procedure.

Failure to do so will severely reduce the life of t he gasket.

e) Clean and inspect each water gauge sight glass. If any water leakage is evident,

renew the sight glass gasket.


Section 7


Standard Warranty for Fulton Boilers Warranty Valid for Models FB-S, FB-C, FB-D

Three (3) Year (36 Months) Material and Workmanship Warranty The pressure vessel is covered against defective material or workmanship for a period of three (3) years from the date of shipment from the factory. Fulton will repair or replace F.O.B. factory any part of the equipment, as defined above, provided this equipment has been installed, operated and maintained by the buyer in accordance with the Installation, Operation & Maintenance Manual. The commissioning agency must also successfully complete and return the equipment Installation and Operation Checklists to Fulton’s Quality Assurance department. This warranty does not cover any failure caused by waterside corrosion or scaling. Therefore, it is imperative that the boiler water management and chemistry be maintained as outlined in the Fulton Installation, Operation & Maintenance Manual, approved practices and recommendations made by Fulton. Parts Warranty Fulton will repair or replace F.O.B. factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within one (1) year of shipment from the factory provided this equipment has been installed, operated and maintained by the buyer in accordance with the Installation, Operation & Maintenance Manual and the component manufacturers’ instructions and the commissioning agency has successfully completed and returned the equipment Installation and Operation Checklists to Fulton’s Quality Assurance department. General Fulton shall be notified in writing as soon as any defect becomes apparent. This warranty does not include freight, handling or labor charges of any kind. These warranties are contingent upon the proper sizing, installation, operation and maintenance of the boiler and peripheral components and equipment. Warranties valid only if the boiler is installed, operated, and maintained as outlined in the Fulton Installation, Operation & Maintenance Manual. No Sales Manager or other representative of Fulton other than the Quality Manager or an officer of the company has warranty authority. Fulton will not pay any charges that were not pre-approved, in writing, by the Fulton Quality Manager. This warranty is exclusive and in lieu of all other warranties, expressed or implied, including but not limited to the implied warranties of merchantability and fitness for a particular purpose. Fulton shall in no event be liable for any consequential or incidental damages arising in any way, including but not limited to any loss of profits or business, even if the Fulton Companies has been advised of the possibility of such damages. Fulton’s liability shall never exceed the amount paid for the original equipment found to be defective. To activate the warranty for this product, the appropriate commissioning sheets must be completed and returned to the Fulton Quality Assurance department for review and approval.

12/2/09


Extended Warranty for Fulton Skid Mounted Steam Boi lers Warranty Valid for Models ICS, ICX, VMP, FB-A, FB-F, FB-L, FB-S

Ten (10) Year Material and Workmanship Warranty The pressure vessel is covered against defective material or workmanship for a period of ten (10) years from the date of shipment from the factory. Fulton will repair or replace at our option, F.O.B. factory any part of the equipment, as defined above, provided this equipment has been installed, operated and maintained in accordance with the Installation, Operation and Maintenance Manual. The commissioning agency must also successfully complete and return the equipment Installation and Operation Checklist to Fulton’s Service Department. This warranty covers any failure caused by defective material or workmanship, however, waterside corrosion or scaling is not covered. Therefore, it is imperative that the boiler water management and chemistry be maintained as outlined in the Installation, Operation and Maintenance Manual. The extended warranty is valid only for steam boilers that are purchased as part of a skid mounted boiler system. Generally, this system MUST include ALL of the following equipment in order for the warranty to apply.

1. Fulton boiler with model number as listed above. 2. Fulton DA or condensate return system with preheat kit. 3. Fulton blowdown tank/separator 4. Water softener 5. Chemical feed system 6. Automatic surface or bottom blowdown, which must operate to maintain TDS levels as specified in the

Installation, Operation and Maintenance Manual. Any deviation or additional equipment specified by Fulton Engineering must be used and maintained per the Installation, Operation and Maintenance Manual There is a $1,000 labor allowance for any failed pressure vessel that is covered under the above warranty. Parts Warranty Fulton will repair or replace FOB factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within twelve (12) months of shipment from the factory provided this equipment has been installed, operated and maintained by the buyer in accordance with approved practices and recommendations made by both Fulton and the component manufacturers. General Fulton shall be notified in writing as soon as any defect becomes apparent. This warranty does not include freight, handling or labor charges of any kind. No Sales Manager or other representative of Fulton other than the Quality Manager or an officer of the company has warranty authority. Fulton will not pay any charges unless they were pre-approved, in writing, by the Fulton Quality Manager. This warranty is exclusive and in lieu of all other warranties, expressed or implied, including but not limited to the implied warranties of merchantability and fitness for a particular purpose. Fulton shall in no event by liable for any consequential or incidental damages arising in any way, including but not limited to any loss of profits or business, even if Fulton has been advised of the possibility of such damages. Fulton’s liability shall never exceed the amount paid for the original equipment found to be defective. Conditions of Warranty Warranties are only valid if the boiler is installed, operated and maintained as outlined in the Installation, Operation and Maintenance Manual. Fulton shall accept no responsibility if the equipment has been improperly installed, operated or maintained or if the buyer has permitted any unauthorized modification, adjustment, and/or repairs to the equipment. The use of replacement parts not manufactured or authorized by Fulton will void any warranty express or implied. Warranty coverage for all components and equipment in said warranty are not valid unless the boiler is started up by a factory certified technician. The commissioning agency must successfully complete and return the equipment Installation and Operation Checklist to Fulton’s Service department. The boiler must be maintained in accordance with the product manual and annual combustion and maintenance reports must be produced for warranty consideration. The warranty is valid for the original installation only in the U.S.A and Canada.


08/20/10


No part of this Installation, Operation, and Mainte nance manual may be reproduced in any

form or by any means without permission in writing from the Fulton Companies.

Fulton Boiler Works, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal Corporation are part of the Fulton

Group of Companies, a global manufacturer of steam, hot water and thermal fluid heat transfer systems.

Caldera Fulton

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